How to route foam?

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How to route foam?

Postby TicklePits » Fri Jul 11, 2014 3:09 pm

How do the pro's do it? Are there any tutorials? I searched but didn't come up with anything.
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Re: How to route foam?

Postby Sir Azrael » Fri Jul 11, 2014 8:28 pm

Having a routing table with the correct routing bit I found is the best way to do what you're asking. It gets pricey though unless you plan on doing it professionally or if you need a routing table for other crafts. The routing bit you'd most likely want to get is a 1/2" cove - then it's just a matter of setting up the table correctly.
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Re: How to route foam?

Postby Sir Thurat » Fri Jul 11, 2014 9:52 pm

I can do a quick video on how to do it with a regular hand router. It takes more time than with a table router or a drill press with a routing bit attached, but it serves the purpose. I'll try to do that tomorrow.
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Re: How to route foam?

Postby TicklePits » Fri Jul 11, 2014 10:10 pm

Thanks all. As it turns out, I have an electric router in my basement. I need to get the right bit for it and I'm good to go. Now, to learn more about 4lb boxes...
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Re: How to route foam?

Postby Sir Thurat » Sat Jul 12, 2014 1:19 pm

Okay, so it turns out my camera is great for photos, and **** for video, so here's the best text tutorial I can give:

Tools:
  • Straight edge
  • Razor
  • Router
  • Appropriately sized core box router bit
  • A jig to guide your router
  • A router guide to go in the jig
  • Clamps
  • Foam

Method:
  1. Gather materials
  2. Insert bit into router
  3. Insert guide into router
  4. Prep foam (measure size of box, cut off puzzle pieces if using puzzle mat, etc.)
  5. Lightly clamp down jig over foam
  6. Zero out router depth based on size of jig, and then set router to appropriate depth for size of core
  7. Do a few passess until the channel is clean
  8. Unclamp project and cut out box
  9. Wash, rinse, repeat, as needed.

If you need some visual representation, let me know and I'll take pictures of the process.
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